220 VAC*DUAL MIG WELDER Model 55525 Assembly And Operation Instructions Due to continuing improvements, actual product may differ slightly from the product described herein. ® 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our website at: http://www.harborfreight.com To prevent serious injury, read and understand all warnings and instructions before use. Copyright© 2007 by Harbor Freight Tools®. All rights reserved.
Contents PRODUCT SPECIFICATIONS.......................................................... 3 GENERAL SAFETY RULES............................................................. 3 Specific Safety Rules................................................................................... 6 Grounding..................................................................................................... 9 Extension Cords..........................................................................................
PRODUCT SPECIFICATIONS Welding Current 35 ~ 110 Amps Duty Cycle Power Consumption 15% @ 110 Amps / 100% @ 35 Amps (Refer to chart and explanation on page 18) 220 Volt / 60 Hz / Single Phase / 24.5 Amps Open Circuit Voltage 40 Volts Maximum Required Power Plug Type 3-Prong, 220 VAC, polarized, twist lock (not included) NEMA #L6-30 or equivalent 14 AWG x 3C x 6’ Long Power Cord Rating (Should be connected to a 25 Amp minimum dedicated circuit) Gas Inlet Size 1 Cables Ground: 6 Gauge, 6’..........
3. Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control. Protect others in the work area from debris such as chips and sparks. Provide barriers or shields as needed. ELECTRICAL SAFETY 1. Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs.
. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the power tool in unexpected situations. 6. Always wear eye, hearing, and breathing protection. For welding safety equipment, refer to number 9 on page 6. TOOL USE AND CARE 1. Use clamps (not included) or other practical ways to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. 2.
Specific Safety Rules 1. Ground this product. This Welder requires the attachment and use of a UL-listed, 220 volt, grounded, 3-prong, electrical Power Cord Plug (not included). Only a qualified electrician should install the Power Cord Plug. Never remove the grounding prong or modify the Power Cord Plug in any way. Do not use adapter plugs with this product.
Prevent accidental fires. Remove any combustible material from the work area. 10. • When possible, move the work to a location well away from combustible materials. If relocation is not possible, protect the combustibles with a cover made of fire resistant material. • Remove or make safe all combustible materials for a radius of 35 feet (10 meters) around the work area. Use a fire resistant material to cover or block all open doorways, windows, cracks, and other openings.
• Follow the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values (TLV’s) for fumes and gases. • Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation. Inhalation Hazard Welding Produces toxic fumes and gasses.
• Use only correct gas shielding equipment designed specifically for the type of welding you will do. Maintain this equipment properly. • Always protect gas cylinders from heat, being struck, physical damage, slag, flames, sparks, and arcs. • Always use proper procedures to move cylinders. 17. Use the right tool for the job. Do not attempt to force small equipment to do the work of larger industrial equipment. There are certain applications for which this Welder was designed.
GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS 1. Tools marked with “Grounding Required” have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet. If the tool should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user, reducing the risk of electric shock. 2. The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool.
ASSEMBLY INSTRUCTIONS WARNING! Always turn off the Welder and unplug the unit from its electrical outlet prior to performing any assembly, maintenance, or service. To Attach The Handle Insert the Handle (4) into the Handle Sockets (3). Then attach the Handle Sockets to the center top of Side Panel (1), using the four Screws provided.
To Route The Wire Note: When installing wire of different size or composition, you will also need to change wire settings, set gun polarity, and, possibly, install gas cylinder. See pages 14-16. 1. IMPORTANT: Securely hold onto the end of the Welding Wire and keep tension on it during the following steps. If this is not done the Welding Wire will spring backward, creating a tangled “bird’s nest” and resulting in wasted wire. (See Figure D.) SPOOL WELDING WIRE 2.
WARNING! EXERCISE EXTREME CAUTION - RISK OF FIRE AND/OR ELECTRIC SHOCK! The following steps require applying power to the Welder. Do not touch anything with the Torch Handle or Welding Wire or an arc will be ignited. Do not touch the internal components of the unit while it is plugged in. 8. Plug the Power Cord (13) into its 220 volt, grounded, electrical outlet. Then, turn the Welder ON. 9. Point the Torch Handle away from all objects.
To Change Wire Settings 1. WARNING! Make sure to turn off the Welder and unplug it from its electrical outlet prior to changing wire settings. 2. Open the Access Panel (12) of the Welder to expose the Wire Feed Assembly. SWING ARM (10a) TENSION ADJUSTING KNOB (10b) FEED ROLLER BRACKET (10k) SCREW (10l) FIGURE G 3. Loosen, and lower the Tension Adjusting Knob (10b) on the Wire Feed Assembly. Then, raise the Swing Arm (10a). (See Figure G.) 4.
Setting The Gun Polarity For Wire Type 1. Set for Electrode Positive (DCEP) for gas welding with solid-core wire. Positive electrode (C), negative ground (D). Shown in illustration, Initial Setup. (See Figure H.) 2. Set for Electrode Negative (DCEN) for gasless flux core wire. Negative electrode (C), positive ground (D). (See Figure H.) 3. C E B When connecting to the weld output terminals, do not place anything between the welding Cable Terminals (A and C) and their copper connections. (See Figure H.
To Install A Gas Cylinder WARNING: Maximum cylinder height is 1 feet 7 inches (0.5m). Maximum cylinder weight is 22 lb., including gas. NEVER exceed either of these maximums. 1. CAUTION! Do not use an Argon/Mixed pressure regulator/flow meter with CO2 shielding gas. To use CO2 shielding gas, you must install a CO2 gas pressure regulator/flow meter (neither one included). 2. Thread the provided strap through the slots on the back of the welder.
OPERATING INSTRUCTIONS Before You Begin Welding Good welding requires a high degree of skill and experience. You should practice a few sample welds on scrap metal before you begin welding your first project. Additional practice periods are recommended whenever you weld a different thickness of material, wire, or weld a different type of connection. Duty Cycle (Duration of Use) 1. CAUTION! Avoid damage to the Welder by not leaving the unit on for more than the prescribed duty cycle time. FIGURE K 2.
Setting Up The Weld WARNING! Before welding, make sure to read and understand all safety precautions and warnings discussed on pages 3 through 10. 1. Overload Indicator Light (28): If too much current is drawn from the Welder, the Overload Protector will activate. The RED Overload Indicator Light will illuminate and the Welder will automatically turn off until it cools down. If this happens, turn the Power Switch to its “OFF” position and wait approximately 20 minutes. (See Figure L.) 2.
6. NOTE: The workpieces should be firmly held together and in position while welding. Use clamps (not included) to hold the workpieces so you can concentrate on the job at hand. The distance (if any) between the two workpieces must be controlled properly to allow the weld to hold both sides securely while allowing the weld to penetrate fully into the joint. 7.
Top figures are Voltage Settings. Bottom number is Wire Speed Setting. .023” .030” .023” .030” Weld Settings Chart FIGURE N Material Thickness (Steel) MIN 1 MIN 2 3 MIN 2 2 5 5 MAX 1 MAX 1 MAX 2 6 4 6 MAX 1 MAX 1 MAX 2 3 4 5 8 MAX 1 MAX 2 MAX 2 6 5 MIN 2 5 7 MAX 1 MAX 1 MAX 2 MAX 2 2 4 MIN 2 MAX 1 MAX 1 MAX 2 MAX 2 3 5 7 MIN 2 1 1 MIN 1 NOTE: The numbers within the spaces are the approximate wire feed/voltage settings recom- .035”-.047” .047”-.075” .075”-.125” .125”-.
17. Set the Wire Speed and Voltage Controls (17, 18, 19) to the recommended start settings as shown in the Weld Settings Chart on the next page. (See Figure N.) 18. Squeeze (and hold) the Trigger Switch (15d) of the Welding Torch (15) and stroke the area to be welded with the Welding Wire to ignite the arc. a. Never tap the Welding Wire into the welding surface to ignite the arc. This will cause the Welding Wire to stick to the workpiece. b.
Weld Diagnosis Weld Penetration Excess or burn-through Weld droops on top and underneath, or falls through entirely, making a hole. Proper Weld is visible underneath and bulges slightly on top. Inadequate Weld does not contact the joint fully, just on the surface. Cross Sections Possible Causes and Solutions Possible Causes and Solutions 1. Excessive material at weld: 1. Workpieces too thick/close: Reduce wire feed speed. Joint design must allow weld to reach bottom of groove and allow proper welding 2.
Porosity Crooked/wavy bead Small cavities or holes in the bead. Top View Top View Possible Causes and Solutions Possible Causes and Solutions 1. Stickout too long: 1. Stickout too long: Reduce stickout. Reduce stickout. 2. Inaccurate welding: 2. Dirty workpiece or welding wire: Use two hands or rest hand on steady Make certain that workpiece and wire are surface. both clean and free from oil, coatings, and other residues. 3. Insufficient gas flow at weld: Increase flow of shielding gas. 4.
When the Weld is Completed 21. Lift the Welding Wire completely away from any grounded object. Set the face shield down. Then, turn the Power Switch to its “OFF” position. 22. Unplug the Power Cord (13) from the electrical outlet. Then, make sure to set the Welding Torch (15) on a nonflammable, nonconductive surface. 23. NOTE: The wire brush/hammer can now be used to clean up the weld. 1. CAUTION! The weld may still be quite hot, and sparks/chips may fly when cleaning.
INSPECTION, MAINTENANCE, AND CLEANING WARNING! Before performing any maintenance on the Welder, unplug the Power Cord (13) from its electrical outlet and allow all components of the Welder to completely cool. 1. Periodically open the Access Panel (12) from the unit and, using compressed air, blow out all dust and debris from the interior. 2. Always store the Welder in a clean, dry, safe location out of reach of children and other unauthorized people. 3.
Replacing The Welding Torch Liner 1. Switch welder off, disconnect power, and discharge electrode to ground before proceeding. 2. Secure welding wire to the spool, cut it near the spool, and remove it from the torch and cable. 3. Gently twist and slide the Locking Collar (15b) off the torch and onto the Protective Sleeve (15a). Slide the Upper Housing (15m) forward and off the Lower Housing (15c). 4. Remove the four Screws (10g) that hold the Cable Clamp (10h) in place.
Parts Lists and Diagrams Wiring Schematic SKU 55525 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
Parts List Part Description Qty. Part Description Qty. 1 Side Panel 1 15g Contact Tip (.
NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. Assembly Diagram SKU 55525 For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
Assembly Diagram (continued) Wire Feed Mechanism (10) 10c 10d 10b 10a 10e 10g 11 10f 10i 10h 10j SKU 55525 10k 10l For technical questions, please call 1-800-444-3353; Troubleshooting section at end of manual.
TROUBLESHOOTING Important! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. Wire feed motor runs but wire does not feed properly Possible Causes and Solutions 1. Insufficient wire feed pressure: Increase wire feed pressure properly - follow instructions on page 12-13. 2. Incorrect wire feed roll size: Replace with the proper one - follow the Wire Settings instructions on page 14. 3.
Troubleshooting (continued) Important! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. Welder does not function when switched on Possible Causes and Solutions 1. Tripped thermal protection device: Shut the welder’s switch to off and allow it to cool for at least 20 minutes. Reduce duration or frequency of welding periods to help reduce wear on the welder. Refer to Duty Cycle section on page 17. 2.
Troubleshooting (continued) Important! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the torch to ground before adjusting, cleaning, or repairing the unit. Wire Feeds, but Shielding gas does not Flow 1. 2. 3. 4. 5. Possible Causes and Solutions Empty Gas Cylinder: Check gas cylinder. Nozzle Plugged: Clean nozzle. If damaged, replace. Regulator or cylinder valve closed: Make sure both valves are adjusted properly.